Wall-mounted storage system

ABSTRACT

A wall-mountable storage system includes a mounting rail having a front face, a rear face, a top face, and a rearwardly inclined surface extending downwardly from the top face toward the rear face; and a panel having a notch that is recessed into a rearward edge of the panel. The notch is configured to allow mounting of the panel in a vertical orientation on the rail without additional exposed hardware. In certain embodiments, a reinforcing liner is disposed in the notch to improve durability of the panel and facilitate the use of unconventional panel materials, such as particleboard.

FIELD OF THE INVENTION

The invention described in this specification relates to wall-mounted storage organizer systems, and more particularly to storage systems having vertical panels supporting shelves or the like, wherein the vertical panels are supported on a horizontally extending rail mounted to a wall.

BACKGROUND OF THE INVENTION

It is now well recognized that the typical closet having one or more hanging rods and one or more shelves supported above the rod or rods does not usually facilitate the most efficient use of the available storage space in the closet. In order to more effectively utilize closet space, various modular-type storage unit systems and closet partition systems have been developed. The preferred modular systems typically are comprised of a few basic components, such as mounting rails, vertical panels, horizontal shelves, hanging rods, and various mounting brackets, which allow the components to be assembled in a variety of different manners to facilitate rearrangement as the needs of a user change. It is desirable that the mounting brackets and other hardware used for assembling the components provide a strong, stable final assembly of the components, and are relatively simple to use to facilitate assembly and disassembly when reconfiguration of the system is desired.

The more popular wall-mounted storage organizer systems generally utilize a bracket that is fastened, usually with screws, to both the rail and a vertical panel. This arrangement, which is described, for example, in U.S. Pat. Nos. 5,222,611 and 5,964,438, have the advantages of facilitating a high level of flexibility in the arrangement of the vertical panels relative to the rail during the initial installation, and providing a very secure attachment of the vertical panels to the rail, whereby unintentional dislodgment of the vertical panels from the rail is improbable. However, the need to utilize separate brackets and fasteners to achieve a secure arrangement involves additional parts and steps during the installation, and, therefore, makes the installation process more time-consuming and difficult. Further, such systems do not allow unrestricted rearrangement of the vertical panels relative to the rail due to limitations based on the location of screw holes developed in the rail during previous installations. Screw holes in the rail from previous installed configurations also detract from the aesthetics of the storage system.

U.S. Pat. No. 3,532,317 discloses a suspensory element for mounting objects on a vertical surface of a mounting element. The disclosed suspensory element is a rail-like member for supporting objects, such as removable letters for signage, having vertically spaced suspending webs projecting forwardly from a mounting portion secured to a vertical surface (e.g., a sign board) with pop rivets. Two identical vertically spaced suspensory elements are used to support an object. The object includes a hook that is received in an upwardly opening channel of the upper suspensory element, and clips that are received into both upwardly and downwardly opening channels of the lower suspensory element. While this arrangement is suitable for supporting removable letters on signs, it is not particularly well-suited for use with wall-mounted storage systems. Specific disadvantages include the requirement for two vertically spaced apart suspensory elements, the need to integrate or attach clips to the suspended article, and an undesirable spacing between the vertical surface (a wall in the case of a storage system) and the suspended object (a vertically oriented panel in the case of a storage system).

U.S. Patent Application Publication No. 2002/0104813 A1 discloses a storage organizer system having a mounting rail and a plurality of storage units adapted to be hung on the rail. Each storage unit includes at least one metal hook extending rearwardly from the unit for engaging the rail and a spacer extending rearwardly from the storage unit for engaging the wall. While this arrangement eliminates the need for a second vertically spaced rail, it has many of the same features and disadvantages of the suspensory element described in U.S. Pat. No. 3,532,317. In particular, the disclosed system requires integrated or attached spacers, and an undesirable spacing between the wall and the storage units. Wall-mounted storage systems in which the vertical panels or sidewalls of the system are flush with the wall are preferred for their improved aesthetics. A further disadvantage is that the arrangement is not particularly secure. A relatively small upward force on a suspended storage unit could cause accidental disengagement of the hook from the rail, since there is nothing in the structure that could inhibit upward movement, other than gravity. It should also be noted that a rod extending between the sidewalls of the storage unit is used for attachment of the hooks to the storage units. These rods are spaced inwardly of the rear wall of the storage units and therefore are clearly visible and further detract from the aesthetics of the system.

U.S. Pat. No. 5,050,832 discloses an adjustable mounting system for removably supporting modular storage units on a vertical wall. The system includes C-shaped brackets and a wall channel. The C-shaped brackets are adjustably mounted on a storage unit, and one of the two opposed hooks on the brackets is hooked over the wall channel. The C-brackets include an outboard flange with a slot and screw hole to facilitate adjustable mounting of the bracket to a modular storage unit. The brackets are partially disposed within a recess in the rearward edge of the vertical panel supported on the channel. Thus, the disclosed arrangement eliminates the need for developing fastener holes (e.g., screw holes) in the mounting rail or channel, and could facilitate flush mounting of the rear edge of the vertical panels with the wall, thereby providing improved aesthetics. However, the flange portion of the bracket is exposed and detracts from the aesthetics of the system. Further, the exposed rail is fabricated from steel or other metal and includes a recess and projecting flanges and webs that further detract from the aesthetics of the system.

U.S. Pat. Nos. 5,819,958 and 4,928,833 each disclose wall-mounted storage systems in which rearward edges of vertical panels are notched to provide an integrated hook for engaging a horizontally oriented rail mounted on a wall, thus completely eliminating separate brackets and thereby achieving improved aesthetics. However, the exposed rail is fabricated from steel or other metal and includes projecting flanges that detract from the aesthetics of the system. Further, the notched panels are susceptible to damage during installation, dismantling, and reconfiguring, and could ultimately fail after repeated reconfigurations of the system.

SUMMARY OF THE INVENTION

The invention provides a wall-mountable storage system in which vertically oriented panels can be mounted to a horizontal rail attached to a wall without any additional exposed mounting hardware, while also facilitating secure mounting of the panels to the rail, and also while facilitating substantially flush mounting of the edges of the panels against the wall.

The wall-mountable storage system of the invention includes a mounting rail having a front face, a rear face, a top face, and a rearwardly inclined surface extending downwardly from the top face toward the rear face; and a panel having a notch recessed into a rearward edge to allow mounting of the panel in a vertical orientation on the rail without additional exposed hardware.

These and other features, advantages and objects of the present invention will be further understood and appreciated by those skilled in the art by reference to the following specification, claims and appended drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is perspective view of a wall-mountable storage system in accordance with the invention.

FIG. 2 is a side elevational view, in partial cross section, showing a vertical panel mounted on the rail of the storage system show in FIG. 1.

FIG. 3 is an edge view of the rear edge of the panel mountable on the rail.

FIG. 4 is an enlarged perspective view of the rail for the storage system.

DESCRIPTION OF THE PREFERRED EMBODIMENT

An illustrated embodiment of the invention is shown in FIGS. 1-4. In the illustrated embodiment, wall-mountable storage system 10 includes a rail 14 mounted on a wall 12, and a plurality of vertically arranged panels 16 suspended from rail 14. Supported on suspended panels 16 are a plurality of shelves 18. Although the invention has been illustrated using a system of vertical panels and shelves, the expression “panel” is intended to encompass the side panel or wall of a cabinet or other storage unit.

As illustrated in FIG. 4, mounting rail 14 includes a flat front face 30, an opposite rear face 32 which abuts a wall to which the rail is mounted, a flat horizontal top face 34, and an inclined surface 36 that extends downwardly from the top face toward the rear face. When rail 14 is secured to wall 12, an upwardly facing recess is defined for receiving a portion of a vertical panel which is defined by a notch 20.

As is shown in FIG. 2, panel 16 includes a notch 20 in a rearward edge of the panel. Notch 20 is configured to allow panel 16 to be easily, securely and stably hooked or hung on rail 14 without requiring any additional brackets or other hardware, and without requiring manipulation of fasteners, such as screws or nails. Notch 20 generally conforms with the shape of rail 14 to facilitate substantially flush mounting of the rearward edges of panel 16 against wall 12. In particular, notch 20 has a depth that is approximately the same thickness as rail 14, or only slightly larger than the thickness of rail 14, an inclined surface that conforms with and engages inclined surface 36 of rail 14, and a vertical dimension that prevents panel 16 from being dislodged from rail 14 unless panel 16 is lifted substantially straight up until the bottom of notch 20 engages the bottom of rail 14, and then moved substantially horizontally away from wall 12. Specifically, the vertical displacement of inclined surface 36 and the space between the bottom of rail 14 and the upwardly facing surface of notch 20 are about the same (e.g., less than 20% different, preferably less than 10% different). Thus, notch 20 and rail 14 are configured to allow easy removal of panel 16 when desired, but to prevent incidental or accidental movements of panel 16 relative to rail 14 from unintentionally dislodging panel 16 from rail 14.

A reinforcement liner or strip 22 is disposed within notch 20 of the illustrated embodiment to strengthen panel 16, and prevent repeated reconfiguring of the system from damaging notch 20 and causing failure of the mounting structure. Reinforcement strip 22 is disposed adjacent to the inclined upper surface of notch 20, and the rearwardly facing vertical surface of notch 20 that generally abuts the front face of rail 14, but does not protrude outwardly from notch 20 beyond the sides of panel 16, and therefore is not visible after installation of panel 16 on rail 14 has been completed. Reinforcement strip or liner 22 can be fabricated of a variety of suitable plastic materials. However, reinforcement strip 22 is preferably fabricated of a metal, such as steel. As shown in FIG. 3, reinforcing liner 22 can be securely attached within notch 20 of panel 16 with mechanical fasteners, such as screws 24. However, adhesives may also be used with or instead of mechanical fasteners.

The configuration (i.e., dimensions and geometry) of rail 14 and notch 20 of panel 16, combined with the reinforcing liner 22, allow rail 14 and panel 16 to be made of any of a variety of materials. Specifically, the design of the wall-mountable storage system of the invention allows rail 14 to be made of conventional mounting rail material such as steel, or less typical materials such as solid wood, plywood or particleboard. Similarly, the invention allows greater flexibility in the selection of materials for panel 16. The expression “particleboard” is intended to encompass any board material made of a combination of cellulose fragments, fibers or particles and a binder or resin matrix that holds the cellulose materials together.

The ability to use a variety of different materials, including relatively inexpensive materials, allows greater flexibility during the manufacturing process, greater variety to the consumer, and lower cost. Additionally, the invention provides greatly improved aesthetics. In particular, the front face of rail 14 can present a completely flat face, free of any recesses or protrusions. In addition, rail 14 can be made of a material that is the same as or matches the appearance of panel 16. Also important is the fact that the invention provides much easier installation, which does not require any additional mounting hardware, such as brackets, and which does not include any exposed mounting hardware that would detract from the aesthetics of the system.

The above description is considered that of the preferred embodiment only. Modifications of the invention will occur to those skilled in the art and to those who make or use the invention. Therefore, it is understood that the embodiment shown in the drawings and described above is merely for illustrative purposes and not intended to limit the scope of the invention, which is defined by the following claims as interpreted according to the principles of patent law, including the doctrine of equivalents. 

1. A wall-mountable storage system, comprising: a mounting rail having a front face, a rear face, a top face, and a rearwardly inclined surface extending downwardly from the top face toward the rear face; a panel having a notch recessed into a rearward edge, the notch configured to allow mounting of the panel in a vertical orientation on the rail without additional exposed hardware.
 2. The wall-mountable storage system of claim 1, wherein the mounting rail is fabricated of wood.
 3. The wall-mountable storage system of claim 1, wherein the mounting rail is fabricated of particleboard.
 4. The wall-mountable storage system of claim 1, wherein the panel is fabricated of particleboard.
 5. The wall-mountable storage system of claim 1, further comprising a reinforcing liner disposed in the notch.
 6. The wall-mountable storage system of claim 5, wherein the reinforcing liner is fabricated of a metal.
 7. The wall-mountable storage system of claim 6, wherein the metal is steel.
 8. The wall-mountable storage system of claim 5, wherein the reinforcing liner is secured in the notch with mechanical fasteners.
 9. The wall-mountable storage system of claim 8, wherein the fasteners are screws.
 10. The wall-mountable storage system of claim 5, wherein the reinforcing liner is secured in the notch with an adhesive material.
 11. The wall-mountable storage system of claim 1, wherein the front face of the rail is flat.
 12. A wall-mountable storage system, comprising: a mounting rail defining an upwardly facing recess; a panel having a notch recessed into a rearward edge, the notch configured to define a portion of the panel that can be received in the upwardly facing recess defined by the mounting rail to allow mounting of the panel in a vertical orientation on the rail without additional exposed hardware; and a reinforcing liner disposed in the notch.
 13. The wall-mountable storage system of claim 12, wherein the mounting rail is fabricated of wood.
 14. The wall-mountable storage system of claim 12, wherein the mounting rail is fabricated of particleboard.
 15. The wall-mountable storage system of claim 12, wherein the panel is fabricated of particleboard.
 16. The wall-mountable storage system of claim 12, wherein the reinforcing liner is fabricated of a metal.
 17. The wall-mountable storage system of claim 16, wherein the metal is steel.
 18. The wall-mountable storage system of claim 12, wherein the reinforcing liner is secured in the notch with mechanical fasteners.
 19. The wall-mountable storage system of claim 12, wherein the reinforcing liner is secured in the notch with an adhesive material.
 20. The wall-mountable storage system of claim 12, wherein the front face of the rail is flat. 